Polymer-based construction materials

ABSTRACT

Aspects described herein are directed to compositions, systems, and methods of manufacturing a polymer-based construction material comprising polymeric resin and filler such as calcium carbonate (CaCO3). A surface of the polymer-based construction material may be treated such that the surface energy is increased from the material&#39;s inherent value to a predetermined value of at least 40 dynes/cm2. Further, the surface energy of the treated surface may persist within 20% of the predetermined value for at least three days.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Non-Provisional patent application claims priority to U.S. patentapplication Ser. No. 16/572,415, filed Sep. 16, 2019, titled“Polymer-Based Construction Materials”, which benefit of co-pending U.S.Provisional Patent Application No. 62/732,447, filed Sep. 17, 2018,titled “Polymer-Based Construction Materials” and both of which arehereby incorporated by reference in their entirety.

BRIEF SUMMARY

A high-level discussion of various aspects of the technology describedherein is provided as an overview of the disclosure and to introduce aselection of concepts that are further described in the detaileddescription section below. This summary is not intended to identify keyfeatures or essential features of the claimed subject matter, nor is itintended to be used as an aid in isolation to determine the scope of theclaimed subject matter.

Polymer-based construction materials, such as vinyl siding, aretraditionally colored by mixing a colorant into the polymer-basedcomposition during manufacture. Painting traditional polymer-basedconstruction materials can be difficult. For example, painting can beinhibited because of additives, such as external lubricants, that lowerthe surface energy of the polymer-based construction material. However,aspects described herein provide polymer-based construction materialsthat retain the advantages of standard materials, while additionallyproviding a window of at least three days for post-manufacture painting.Further, aspects described herein provide improved paint wet-out duringthe paint application process. Following application of paint, aspectsdescribed herein can provide an enhanced bond between the paint and thesurface of the polymer-based construction material.

BACKGROUND

Polymer-based construction materials are currently manufactured, forexample, using extrusion technology. However, polymer-based materialscan be difficult to paint. For example, adhesion of typical exteriorlatex paint to current formulations of polymer-based constructionmaterial is relatively poor without proper traditional preparation withadditional coatings and processes. In some cases, the interfacialtension of the material can be substantially lower than that of modernwater-based exterior latex paints. This is problematic for both endusers and to industrial pre-finish operations that desire colors otherthan as-manufactured colorations.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments of the present invention are described indetail below with reference to the attached drawing figures, andwherein:

FIG. 1 depicts an example system, according to aspects described herein;

FIG. 2A depicts an example method for the post-manufacturing treatmentof a polymer-based construction material, according to aspects describedherein;

FIG. 2B depicts an example method for the manufacture and treatment of apolymer-based construction material, according to aspects describedherein;

FIGS. 3A, 3B, and 3C depict various views of an example polymer-basedconstruction material, according to aspects described herein; and

FIG. 4 depicts a comparison of the surface energy of treatedpolymer-based construction materials in accordance with aspectsdescribed herein to a traditional and untreated construction material.

DETAILED DESCRIPTION

The subject matter of the technology described herein is described withspecificity to meet statutory requirements. However, the descriptionitself is not intended to limit the scope of this patent. Rather, theinventors have contemplated that the claimed subject matter might alsobe embodied in other ways, to include different steps or combinations ofsteps similar to the ones described in this document, in conjunctionwith other present or future technologies. Moreover, although the terms“step” and/or “block” may be used herein to connote different elementsof the methods employed, the terms should not be interpreted as implyingany particular order among or between various steps herein disclosedunless and except when the order of individual steps is explicitlydescribed.

As used herein, the term “paint” and the term's various forms refers toa pigment containing material (commonly referred to as paint, dye,stain, and so on); an adhesive or adhesion promoter (such as a primer);a transparent, semi-transparent, or opaque luster altering material(such as materials that increase, decrease, preserve or otherwise modifyreflectivity, sheen, or gloss); and a protectant. As such, the term“painting” is the application of “paint,” as defined above.

As used herein, polymer-based construction materials include foamed andnon-foamed polymer-based compositions unless and except where expresslyand explicitly stated otherwise. Polymer-based construction materialscan include trim components (e.g. trim boards), siding components (e.g.siding boards, siding shingles, siding sheets), roofing components (e.g.roofing boards, roofing shingles, roofing sheets), decking components(e.g. decking boards, decking sheets, deck flooring, deck railings),decorative and/or functional construction accessories, and any otherconstruction materials. Additionally, polymer-based constructionmaterials can be assembled to form a corner board, column wrap, postcover, molding, or any other multi-component construction material.

Plasma is an ionized gas and is one of the four fundamental states ofmatter. Plasma is a gas (e.g., multiple element gas and single elementgas) into which sufficient energy is provided to free electrons fromatoms or molecules and to allow both species, ions and electrons, tocoexist. Stated differently, plasma is an ionized gas consisting ofpositive ions and free electrons in proportions resulting in more orless no overall electric charge. Plasma may exist in both a thermal anda non-thermal form. The distinction between thermal and non-thermal maybe determined by the temperature of electrons, ions, and neutrals.Thermal plasmas have electrons and the heavy particles at substantiallythe same temperature, i.e., they are in thermal equilibrium with eachother. Non-thermal plasmas have the ions and neutrals at a much lowertemperature, whereas electrons are at a significantly greatertemperature. Aspects provided herein rely on a non-thermal plasma forincreasing the surface energy of at least one surface of a polymer-basedconstruction material from the material's inherent surface energy to apredetermined surface energy, in accordance with an exemplary aspect.

While the use of polymer-based construction materials in constructionprojects provide a number of beneficial results, polymer-basedconstruction materials with traditional composition and surfacetreatment have limitations. Namely, post-manufacture painting optionsare limited. For example, adhesion of traditional exterior latex paintsto current formulations of polymer-based construction materials isrelatively poor, as the interfacial tension of the material is typicallysubstantially lower than modern water-based exterior latex paints.

Said another way, the drying and adhesive bond characteristics ofpainted polymer-based products (such as polyvinyl chloride products)using current product formulations is far from ideal. For end users,painting may require solvent wipes, sanding, tack cloth wipes, and othersteps before the paint can even be applied. This preparation work isadded labor and risk. Further, the formation of the adhesive bondbetween traditional polymer-based construction material and paint isslow, often requiring days or weeks to reach a full strength of 5Badhesion (as measured by ASTM D3359 cross hatch adhesion tests detailedin the 2018 volume of ASTM Tests for Chemical, Physical, and OpticalProperties). Pre-finish operations encounter similar problems but may befurther hindered because of the limited manual and automated handlingthat can be performed as the construction material and paint bond.

One way to address this problem is to increase the surface energy(dynes/cm²) of the polymer-based construction material. A sufficientlylarge increase in the surface energy may facilitate adhesion of paintapplied to the surface of the polymer-based construction material.Accordingly, as provided herein, the recited polymeric compositioncomprising polymer resin, filler—such as calcium carbonate (CaCO₃)—and,in some aspects, titanium oxide (TiO₂) is treated such that the surfaceenergy is increased to at least 40 dynes/cm² through mechanical ornon-mechanical methods. Further, this surface energy increase persistswithin 20% of the increased value for at least three days from thetreatment of the surface. Specific compositions and surface treatmentsare provided herein that are capable of achieving and maintaining atarget minimal surface energy capable of allowing a sufficient bondstrength between the polymer-based construction material and the paintapplied later in time (e.g., at least three days after the extrusion ofthe polymer-based material). Additionally, some aspects described hereinfacilitate the application of exterior paints to the polymer-basedconstruction material with an adhesion of 4B-5B at least three dayspost-treatment (in some aspects, at least one month, three months, sixmonths, or twenty months).

With reference to FIG. 1, an example system 100 is provided inaccordance with aspects described herein. Generally, system 100facilitates the manufacture of a polymer-based construction material andtreatment of a surface of the polymer-based construction material. Insome aspects, the polymer-based construction material comprises apolymeric resin, a filler (such as CaCO₃), and ≤7% TiO₂. The treatmentincreases the surface energy of the surface from an inherent value to apredetermined value of at least 40 dynes/cm². Additionally, the surfaceenergy persists within 20% of the predetermined value for at least threedays. Said another way, aspects of system 100, method 200, and method210 facilitate the production of a polymer-based construction material,such as polymer-based construction material 302, with an enhancedsurface energy that persists for at least three days. Some aspects ofsystem 100 comprise a pre-mix ingredient storage container 102, hotmixer 112, cold mixer 114, post-mix blend storage container 116,extruder 118, extrusion die 120, post-extrusion sizing process 122, anda post-extrusion treatment process that increases the surface energy ofa surface of the polymer-based construction material to at least 40dynes/cm².

Turning to FIG. 2B and with continued reference to FIG. 1, a method 210for the production and treatment of a polymer-based constructionmaterial in accordance with aspects described herein is provided. Insome aspects, method 210 may be facilitated by system 100. In an exampleaspect, at block 212 a polymer-based construction material is produced.The production of the polymer-based construction material begins, insome aspects, at a pre-mix ingredient storage container, such as pre-mixingredient storage container 102. Ingredient storage container 102 mayhold a polymeric resin 104, filler 106, and TiO₂ 108 in independentstorage vessels. The polymeric resin 104 can comprise one or more (orany combination thereof) polyvinyl chloride (PVC); acrylonitrile;alpha-olefins such as ethylene, propylene, etc.; chlorinated monomerssuch as vinylidene, dichloride; acrylate monomers such as acrylic acid,methylacrylate, methyl-methacrylate, acrylamide, hydrox-ethyl acrylate,and others; styrenic monomers such as styrene, alpha methyl styrene,vinyl toluene, etc.; vinyl acetate; and other commonly availableethylenically unsaturated monomer compositions.

In some aspects, the polymeric resin 104 does not include a plasticizer,such as diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), orsimilar compounds. The omission of a plasticizer may enhance thepolymer-based construction material's retention of subsequent increasesto surface energy. For example, a plasticizer may be omitted, in someembodiments, such that the matrix of the polymer-based constructionmaterial retains increases to the surface energy (by for example, themechanical and/or non-mechanical treatments described herein) for atleast three days. Additionally, the polymeric resin 104 can includevirgin polymeric resin(s) and recycled polymeric resin(s). As usedherein, a virgin polymeric resin refers to a resin that includes atleast one polymer that is not recycled or a recovered scrap.

In some aspects, filler 106 comprises one, more than one, or anycombination of: CaCO₃ or compounds (naturally occurring, refined,manufactured, or produced) containing CaCO₃, such as limestone,dolomite, aragonite, precipitated CaCO₃, and so forth; fieldstone;granite; and clay and clay containing compounds such as talc, smectite,calcium silicates, aluminum silicates, and so forth. Further, in someaspects, ingredient storage container 102 holds additional ingredients110, such as a thermal stabilizer, acrylic process aid, internal andexternal lubricants, wax, pigment, and/or a blowing agent. Additionally,ingredient storage container 102 may comprise a molecular sieve, in someaspects. In some aspects, the additional ingredients 110 includes a highmolecular weight (BMW) acrylic process aid, such as 2-Propenoic acid,2-methyl-, methyl ester, polymer with butyl 2-propenoate andethenylbenzene acid or other similar compounds. The acrylic modifier mayenhance the polymer-based construction material's retention ofsubsequent increases to surface energy. For example, the acrylicmodifier may be included, in some embodiments, to modify the matrix ofthe polymer-based construction material such that post-extrusionincreases to the surface energy (by for example, the mechanical and/ornon-mechanical treatments described herein) can be retained for at leastthree days.

Some aspects of block 212 further comprise mixing a predetermined amountof each of the polymeric resin 104, filler 106, and TiO₂ 108. The mixingmay be facilitated by adding the materials from the ingredient storagecontainer 102 to a hot mixer 112 and/or a cold mixer 114 through avacuum transfer system, volumetric feeder, gravimetric feeder, or othersimilar processes. The predetermined amount of each material may varybased on the desired properties and intended use of the resultingpolymer-based construction material. In some aspects, the mix comprises:between 45% and 90% of polymeric resin 104 by weight or mass; ≥5% fillerby weight or mass; and ≤7% TiO₂ by weight or mass. In some aspects, themix comprises: between 45% and 85% of polymeric resin 104 by weight ormass; ≥8% CaCO₃ by weight or mass; and ≤7% TiO₂ 108 by weight or mass.In some aspects, the additional ingredients 110 comprise between 5% and20% of the mix by weight or mass. For a non-limiting illustrativeexample, for a mix with a target weight of 100 lbs a vacuum transfersystem may deposit 75 lbs of polymeric resin(s) 104, 10 lbs of filler106 (such as CaCO₃), and 0.75 lbs of TiO₂ 108 into hot mixer 112. Thisinitial mix may be blended in the hot mixer 112 until satisfactorilyhomogenous. The initial mix may then be transferred to cold mixer 114and 14.25 lbs of additional ingredients may be added resulting in 100lbs of mix. The mix may continue to blend in the cold mixer 114 untilsatisfactorily homogenous.

Some aspects of block 212 further comprise aging the mixed material fora predetermined period of time. For example, some aspects of system 100transfer the mixed material from a mixer to a post-mix blend storagecontainer 116 through a vacuum transfer system, volumetric feeder,gravimetric feeder, or other similar processes. The predetermined periodof time may be less than 6 hours, at least 6 hours, at least 12 hours,or at least 24 hours. The post-mix blend storage container 116 may storemixes of different compositions in separate aging vessels.

Some aspects of block 212 further comprise extruding the initial mix orthe aged mix into a sheet of a pre-treatment polymer-based constructionmaterial. For example, after the predetermined period of time haselapsed, the aged mix can be transferred to an extruder, such asextruder 118. In a non-limiting example, extruder 118 comprises a twinscrew extruder. The extruder 118 may force the aged mix through anextrusion die 120 of the desired gauge and cross-sectional pattern. Thegauge may be any thickness, such as those described in relation to gauge308. The density of the polymer-based sheet may vary determined based onthe intended final use of the material. For example, the polymer-basedsheet may be a cellular or foamed polymer-based material of varieddensity.

The newly formed polymer-based sheet may be cooled after exiting theextrusion die 120 via calender rolls, conveyers, or any other suitablesystem. In some aspects of block 212, the foamed sheet can be dividedinto two, more than two, or a plurality of sheets of uniform ornon-uniform widths and lengths, such as described in relation to width318 and length 306 of FIG. 3. Accordingly, the foamed sheet can betransported by conveyers or any other suitable means to post-extrusionsizing process 122, in some aspects of system 100. As will be understoodby those skilled in the art, the temperature suitable for division canvary based on the specific composition of the mix used to manufacturethe foamed sheet, the technique used to divide the foamed sheet bypost-extrusion sizing process 122, manufacturing tolerances, and/orother factors. Post-extrusion sizing process 122 can be a manuallyoperated or computer controlled saw, pressurized liquid cutting device,pressurized gas cutting device, or any other suitable cutting device. Insome aspects, scrap portions (also referred to as regrind, recycled, orrecovered) of the foamed sheet can be ground and reused as an additionalingredient 110 or a mix in post-mix blend storage container 116.

At block 214, the surface of a polymer-based construction material istreated such that the surface energy is increased from the inherentsurface energy to a predetermined value. In an example aspect, theinherent surface energy is between 30 and 38 dynes/cm². In aspects, thepredetermined value is greater than or equal to (“≥”) 40 dynes/cm². Forexample, in an aspect, the predetermined value is between 40 dynes/cm²and 80 dynes/cm². In an aspect, the predetermined value is between 40dynes/cm² and 75 dynes/cm². In an aspect, the predetermined value isbetween 45 dynes/cm² and 75 dynes/cm². In an aspect, the predeterminedvalue is between 50 dynes/cm² and 60 dynes/cm². In an aspect, thepredetermined value is between 50 dynes/cm² and 58 dynes/cm². In anaspect, the predetermined value is between 45 dynes/cm² and 60dynes/cm². Different predetermined values may be selected for differentcompositions, materials, intended duration of pre-painting window, andthe like.

At block 214, a surface of the polymer-based construction material istreated. In some aspects of block 214, the polymer-based constructionmaterial is the sized sheet(s) or the foamed sheet from block 212. Thetreatment may comprise a mechanical treatment, a non-mechanicaltreatment, or any combination thereof to the surface of thepolymer-based construction material. For example, in an aspect, system100 may comprise a mechanical treatment device 126 that intentionallyscuffs, sands, grinds or abrades a surface of the polymer-basedconstruction material such that the surface energy of the surface isincreased to the predetermined value 128. The sanding or scuffingtreatment may be facilitated using an orbital sander, random orbitalsander, rotary brush, rotary sander, cylindrical sander, block sander,hand sander, or any other device suitable for mechanically scuffing,sanding, or abrading a surface. In a non-limiting example aspect, themechanical treatment device 126 sands the surface of the polymer-basedconstruction material with between 16 grit and 300 grit material (or itsequivalent) such that the surface energy is increased from thepolymer-based construction material's inherent surface energy to thepredetermined surface energy (or to a surface energy above the inherentsurface energy when a secondary process is performed to increase thesurface energy to the predetermined surface energy). In some aspects,mechanical treatment can be advantageous where non-mechanical treatmentmay cause the unintentional weakening of internal polymeric bonds ofsome compositions of the polymer-based construction material describedherein. For example, due to thermal energy exposure during somenon-mechanical treatments, a degradation of polymeric attributes mayoccur. Therefore, a mechanical treatment is a suitable alternative insome of these aspects.

Additionally, or alternatively, the treatment comprises a non-mechanicalthermal, flame, plasma, corona treatment, or coating treatment to thesurface of the polymer-based construction material. Accordingly, system100 may comprise a non-mechanical treatment device 124 such as a plasmatorch, a corona treatment system, or a coating system. Because someaspects of the mechanical treatment may remove a measurable thickness ofthe polymer-based construction material's outer-surface, non-mechanicaltreatment may be advantageous where mechanical treatment may causeunintentional exposure of the polymer-based construction materialsinternal matrix. For an illustrative example, non-mechanical treatmentmay be advantageous for some compositions of foamed polymer-basedconstruction materials where mechanical treatment may expose theinternal foam matrix. In an exemplary aspect, the plasma torch is aplasma generator that utilized a multi-gas composition (e.g.,atmospheric air) to form the plasma. For example, it is contemplatedthat the application of plasma to the component occurs at atmosphericpressure, which allows for a continuous processing (rather than batchprocessing). Plasma generated at atmospheric conditions is referred toas atmospheric pressure plasma. The plasma torch generates plasma by ahigh voltage between an anode and cathode, which is blown out through anozzle on the plasma torch with a working gas, such as atmospheric air.The frequency of energy and a pulsing pattern (e.g., single pulse ofenergy, double pulse of energy) of the energy may be varied to form theplasma, in some aspects. It is contemplated that a rotary nozzle may beimplemented to apply plasma in a pulse-like manner to limit the heatinput to the surface, which could deform, discolor, or otherwisenegatively affect a polymer-based construction material. The nozzle andthe number of plasma application passes may be adjusted to achieve adesired surface energy while maintaining a temperature below apredefined value, in an exemplary aspect. For example, and with briefreference to FIGS. 3A and 3B, a first surface 304 of polymer-basedconstruction material 302 can be treated with ionized plasma such thatthe surface energy increases from the polymer-based constructionmaterial's inherent surface energy to the predetermined surface energy(or to a surface energy above the inherent surface energy when asecondary process is performed to increase the surface energy to thepredetermined surface energy).

In another exemplary aspect, a corona treatment system applieshigh-frequency power through a ceramic or metal electrode array acrossan intentional air gap onto the surface of the polymer-basedconstruction material. The corona device can be a bare roller, a coveredroller, or any other corona device. A corona treatment system generatesan ionized corona discharge that increases the surface energy of thesurface. The corona treatment system can increase the surface energy ofa surface of the polymer-based construction material from its inherentsurface energy to the predetermined surface energy. For example, andwith brief reference to FIGS. 3A and 3B, a first surface 304 ofpolymer-based construction material 302 may be treated by the coronatreatment system such that the ionized blown gas is incorporated intothe first surface 304. As a result, the surface energy of the firstsurface 304 may increase from the polymer-based construction material'sinherent surface energy to the predetermined surface energy (or to asurface energy above the inherent surface energy when a secondaryprocess is performed to increase the surface energy to the predeterminedsurface energy). In some aspects, corona treatment can be advantageousas the precision and relatively low temperature of the corona electrodearray may facilitate uniform surface energy enhancement of somecompositions of the polymer-based construction material describedherein.

In yet another exemplary aspect, a coating system applies at least oneof a coating of UV curable monomers, oligomers, adhesion promoters,primers, photoinitiators, and pigments. Additionally, in some aspects,the coating may comprise an acrylate, such as THF acrylate, beta carboxyethyl acrylate, ethyl hexyl acrylate, N-vinyl pyrolidone, and any otheracrylate compound. The coating system may comprise one or more computeror manually controlled sprayers, vacuum applicator, curtain coater, slotdie applicator, and roll coater. As an illustrative example, apre-metered coating with a viscosity between 300 and 2000 cP is appliedto the surface of the polymer-based construction material by a curtaincoater. Turing briefly to FIG. 3C, and with continued reference to FIG.1, the coating system may apply the coating 320 with a thickness ofbetween 5 and 37 microns to at least surface 304 of the polymer-basedconstruction material 302. In some aspects, the coating 320 is appliedwith a thickness of between 10 and 30 microns. In some aspects, thecoating 320 is applied with a thickness of between 12 and 25 microns.After the coating 320 is applied to the surface 304, the polymer-basedconstruction material 302 can be treated with radiation from a mercuryarc lamp, microwave powered sealed mercury arc lamp, and/or UV LED arrayincorporated with or independent from the coating system until thecoating is cured. The radiation can be of a wavelength between 350 nmand 410 nm. In an aspect, the wavelength is between 385 nm and 405 nm.Because a coating with a viscosity between 300 and 2000 cP is applied inan example from a curtain coater, with a thickness between 10 and 30microns, and cured by radiation with a wavelength between 350 nm and 410nm; the surface energy must be increased to at least 40 dynes/cm².Additionally, subsequent painting can achieve an adhesive bond of atleast 4B bond at least 3 days after coating.

At least one advantage provided by method 210 in combination with thecompositions described herein may be that the surface energy of thetreated surface persists for significantly longer periods of time thanpreviously believed possible. In some aspects of method 210, the surfaceenergy of the polymer-based construction material manufactured inaccordance with block 212 and treated in accordance with aspects ofblock 214 persists within 20% of the predetermined surface energy for ≥3days. In some aspects, the post-treatment surface energy persists within20% of the predetermined surface energy for ≥1 month. In some aspects,the post-treatment surface energy persists within 20% of thepredetermined surface energy for ≥3 months. In some aspects, thepost-treatment surface energy persists within 20% of the predeterminedsurface energy for ≥6 months. In some aspects, the post-treatmentsurface energy persists within 20% of the predetermined surface energyfor ≥20 months. Said another way, method 210 and/or the compositionsdescribed in relation to method 210 may enable temporary storage ofpolymer-based construction material in a warehouse, retailer, and/or soon (collectively 130), without painting, for a period of timepost-treatment 132. For an example, a post-manufacturing finisher,contractor, end user, or any other person or entity may acquire and holdthe polymer-based construction material without painting (as indicatedat 140), for a period of time post-treatment 132. The polymer-basedconstruction material may then be painted 142 when needed, ordered, orotherwise requested. For example, a post-manufacturing finisher maystore an unpainted polymer-based construction material post-treatment,until an order for a specific color of painted polymer-basedconstruction material is requested. The post-manufacturing finisher maythen paint 142 the polymer-based construction material and the paintedmaterial can be used for its intended purpose, such as siding for abuilding 144, decking, shingles, trim, or any other suitable purpose.

Additionally, or alternatively, the polymer-based construction materialmay be transported 134 to and used for its intended purpose, withoutpainting, for a period of time post-treatment 132. For an illustrativeexample, the intended purpose can be siding of a building 136, decking,shingles, trim, or any other suitable purpose. Later the polymer-basedconstruction material can be painted 138 at least partially, because thecomposition of the polymer-based construction material enables thepost-treatment surface energy to persist within 20% of the predeterminedsurface energy for ≥3 days, ≥1 month, ≥3 months, ≥6 months, or ≥20months. Accordingly, the recited polymeric composition comprising CaCO₃and ≤7% TiO₂ that is treated to have a surface energy of at least 40dynes/cm² through aspects of block 214 is able to have a surface energythat persists within 20% for at least three days from the treatment ofthe surface. The surface energy may be tested by, for example, a dynepen or any other suitable testing method. Although FIG. 1 depicts thepolymeric composition in a siding form factor, it is contemplated thatthe polymeric composition can take any form. For example, thepolymer-based construction materials can be assembled to form decking,shingles, trim, a corner board, column wrap, post cover, molding, or anyother single component or multi-component construction material.

Turning now to FIG. 2A, a method 200 of preparing a polymer-basedconstruction material for future painting is provided in accordance withaspects described herein. Generally, method 200 comprises increasing thesurface energy of the surface of a polymer-based construction materialfrom its inherent surface energy to ≥40 dynes/cm² through a treatment.Said another way, the surface energy of a polymer-based constructionmaterial may be increased from a first surface energy to a secondsurface energy of at least 40 dynes/cm² in response to treatment of thesurface. In some aspects, the surface energy of the surface persistswithin 20% of the second surface energy for at least three days. In someaspects, the polymeric composition of the polymer-based constructionmaterial comprises a polymeric resin, one or more fillers, and titaniumoxide (TiO₂). In an example aspect, the filler includes CaCO₃. Method200 can be used to treat the polymer-based construction material, suchas the polymer-based construction material 302 (as described inreference to FIGS. 3A, 3B, and 3C). Further, some aspects of method 200can be facilitated by some or all of system 100.

Some aspects of method 200 begin at block 202 with the treatment of asurface of a polymer-based construction material. The treatment maycomprise a mechanical treatment, a non-mechanical treatment, or anycombination thereof to the surface of the polymer-based constructionmaterial. For example, in an aspect, the treatment comprises themechanical sanding or scuffing of the surface. In some aspects,mechanical treatment can be advantageous where non-mechanical treatmentmay cause the unintentional weakening of internal polymeric bonds ofsome compositions of the polymer-based construction material describedherein. The sanding or scuffing treatment may be facilitated using anorbital sander, random orbital sander, rotary brush, rotary sander,cylindrical sander, block sander, hand sander, or any other device formechanically scuffing, sanding, or abrading a surface. In an exampleaspect, the mechanical treatment device 126 sands the surface of thepolymer-based construction material with between 16 grit and 300 gritmaterial (or its equivalent) such that the surface energy is increasedfrom the polymer-based construction material's inherent surface energyto a predetermined surface energy. In aspects, the surface treatment isperformed on 80%, 90%, 95%, or 100% of a surface of the article. This isin contrast to accidental operation that occur at finite locations of asurface, such as through inadvertent mechanical operations on finiteportions of a polymer article during a construction project. As theultimate goal is to achieve a sufficient paint bond allowing for auniform and consistent appearance from the application of paint onto thetreated surface, inadvertent and accidental mechanical operations onsmall portions of a surface will not achieve a uniform and consistentpainted surface.

In some aspects, the treatment at block 202 comprises a non-mechanicalthermal, flame, plasma, corona treatment, or coating treatment to thesurface of the polymer-based construction material. Because somemechanical treatments in certain aspects may remove a measurablethickness of the polymer-based construction materials outer-surface,non-mechanical treatment may be advantageous where mechanical treatmentmay cause unintentional exposure of the polymer-based constructionmaterials internal matrix. For an illustrative example, non-mechanicaltreatment may be advantageous for some compositions of foamedpolymer-based construction materials where mechanical treatment mayexpose the internal foam matrix. In an exemplary aspect, the plasmatorch is a plasma generator that utilizes a multi-gas composition (e.g.,atmospheric air) to form the plasma. For example, it is contemplatedthat the application of plasma to the component occurs at atmosphericpressure, which allows for a continuous processing (rather than batchprocessing). Plasma generated at atmospheric conditions is referred toas atmospheric pressure plasma. The plasma torch generates plasma by ahigh voltage between an anode and cathode, which is blown out through anozzle on the plasma torch with a working gas, such as atmospheric air.The frequency of energy and a pulsing pattern (e.g., single pulse ofenergy, double pulse of energy) of the energy may be varied to form theplasma, in some aspects. It is contemplated that a rotary nozzle may beimplemented to apply plasma in a pulse-like manner to limit the heatinput to the component, which could deform or otherwise negativelyaffect a polymer-based material. The nozzle and the number of plasmaapplication passes may be adjusted to achieve a desired surface energywhile maintaining a temperature below a predefined value, in anexemplary aspect. For example, and with brief reference to FIGS. 3A and3B, a first surface 304 of polymer-based construction material 302 canbe treated with ionized plasma such that the surface energy increasesfrom the polymer-based construction material's inherent surface energyto the predetermined surface energy (or to a surface energy above theinherent surface energy when a secondary process is performed toincrease the surface energy to the predetermined surface energy).

In another exemplary aspect of block 202, a corona treatment systemapplies high-frequency power through a ceramic and/or metal electrodearray across an intentional air gap onto the surface of thepolymer-based construction material. The corona device can be a bareroller, a covered roller, or any other corona device. A corona treatmentsystem generates an ionized corona discharge that increases the surfaceenergy of the surface. In an aspect, the corona treatment system alsoperforms a backside treatment. In an example aspect, the non-mechanicaltreatment device 124 increased the surface energy of a surface of thepolymer-based construction material's inherent surface energy to apredetermined surface energy. For example, and with brief reference toFIGS. 3A and 3B, a first surface 304 of polymer-based constructionmaterial 302 may be treated by the corona treatment system such that theionized blown gas is incorporated into the first surface 304. As aresult, the surface energy of the first surface 304 may increase fromthe polymer-based construction material's inherent surface energy to thepredetermined surface energy (or to a surface energy above the inherentsurface energy when a secondary process is performed to increase thesurface energy to the predetermined surface energy). In some aspects,corona treatment can be advantageous as the precision and relatively lowtemperature of the corona electrode array may facilitate uniform surfaceenergy enhancement of some compositions of the polymer-basedconstruction material described herein.

In yet another exemplary aspect, block 202 comprises application of atleast one of a coating of UV curable monomers, oligomers, adhesionpromoters, primers, photoinitiators, and pigments. Additionally, in someaspects, the coating may comprise an acrylate, such as THF acrylate,beta carboxy ethyl acrylate, ethyl hexyl acrylate, N-vinyl pyrolidone,and any other acrylate compound to a surface of the polymer-basedconstruction material. The coating system may comprise one or morecomputer and/or manually controlled sprayers, vacuum applicators,curtain coater, slot die applicators, and/or roll coating. As anillustrative example, in an aspect, a pre-metered coating with aviscosity between 300 and 2000 cP is applied to the surface of thepolymer-based construction material by a curtain coater. Turning brieflyto FIG. 3C, and with continued reference to FIG. 2A, the coating systemmay apply the coating 320 with a thickness of between 5 and 37 micronsto at least surface 304 of the polymer-based construction material 302.In some aspects, the coating 320 is applied with a thickness of between10 and 30 microns. In some aspects, the coating 320 is applied with athickness of between 12 and 25 microns. After the coating 320 is appliedto the surface 304, the polymer-based construction material 302 can betreated with radiation from a mercury arc lamp, microwave powered sealedmercury arc lamp, and/or UV LED array, incorporated with or independentfrom the coating system, until the coating is cured. The radiation canbe of a wavelength between 350 nm and 410 nm. In an aspect, thewavelength is between 385 nm and 405 nm. Because a coating with aviscosity between 300 and 2000 cP is applied in an example from acurtain coater, with a thickness between 10 and 30 microns, and cured byradiation with a wavelength between 350 nm and 410 nm, the surfaceenergy of the polymer-based construction material must be increased toat least 40 dynes/cm². Additionally, subsequent painting of the coatedsurface can achieve an adhesive bond of at least 4B bond at least 3 daysafter coating.

In response to the treatment, the surface energy of the polymer-basedconstruction material increases to at least 40 dynes/cm² at block 204.In some aspects, the surface energy may be increased to a predeterminedvalue ≥40 dynes/cm². For example, in an aspect, the predetermined valueis between 40 dynes/cm² and 70 dynes/cm². In an aspect, thepredetermined value is between 45 dynes/cm² and 65 dynes/cm². In anaspect, the predetermined value is between 50 dynes/cm² and 60dynes/cm². In an aspect, the predetermined value is between 50 dynes/cm²and 58 dynes/cm². In an aspect, the predetermined value is between 45dynes/cm² and 60 dynes/cm². In an aspect, the predetermined value isbetween 40 dynes/cm² and 60 dynes/cm². In some aspects, the surfaceenergy of the polymer-based construction material's surface persistswithin 20% of the predetermined surface energy for at least three days.For example, if the predetermined surface energy is between 40 dynes/cm²and 70 dynes/cm², the surface energy of the polymer-based constructionmaterial's surface persists between, at least, 32 dynes/cm² and 56dynes/cm² for at least three days.

At least one advantage provided by method 200 may be that the surfaceenergy of the treated surface persists for significantly longer periodsof time than previously believed possible. For example, it is a commonbelief that painting of polymer-based construction materials shouldoccur within minutes and no more than a few hours post-treatment.However, in some aspects of method 200, the surface energy of thepolymer-based construction material, such as polymer-based constructionmaterial 302, treated in accordance with aspects of block 202 persistswithin 20% of the predetermined surface energy for ≥3 days, at block204. In some aspects, the post-treatment surface energy persists within20% of the predetermined surface energy for ≥1 month. In some aspects,the post-treatment surface energy persists within 20% of thepredetermined surface energy for ≥3 months. In some aspects, thepost-treatment surface energy persists within 20% of the predeterminedsurface energy for ≥6 months. In some aspects, the post-treatmentsurface energy persists within 20% of the predetermined surface energyfor ≥20 months. Said another way, method 200 may further comprisetemporary storage of polymer-based construction material in a warehouse,retailer, and so on (collectively 130), without painting, for a periodof time post-treatment 132. Additionally, and/or alternatively, thepolymer-based construction material may be transported to and used forits intended purpose, without painting, for a period of timepost-treatment 132. Later (such as ≥3 days, ≥1 month, ≥3 months, ≥6months, ≥20 months) the polymer-based construction material may bepainted at least partially because the post-treatment surface energypersists within 20% of the predetermined surface energy for ≥3 days, ≥1month, ≥3 months, ≥6 months, or ≥20 months. Said another way, therecited polymeric composition comprising CaCO₃ and ≤7% TiO₂ that istreated to have a surface energy of at least 40 dynes/cm² throughaspects of block 202 may be able to have a surface energy that persistswithin 20% for at least three days from the treatment of the surface.The surface energy may be tested by, for example, a dyne pen or anyother suitable testing method.

With reference to FIGS. 3A, 3B, and 3C, an example polymer-basedconstruction material is provided in accordance with aspects describedherein. The polymer-based construction material 302 may be a trimcomponent (e.g. trim board), a siding component (e.g. siding board,siding shingle, or a siding sheet), a roofing component (e.g. roofingboard, roofing shingle, roofing sheet), corner board component, a columnwrap component, a post cover component, a molding component, a deckingcomponent (e.g. decking board, decking sheet, deck flooring, deckrailing), a decorative and/or functional construction accessory, or anyother construction material(s). Additionally, in some aspects, thepolymer-based construction material 302 can be used as a painting canvasor any other material for artistic expression. The polymer-basedconstruction material 302 comprises a polymeric resin, one or morefillers, and TiO₂. In an example aspect, the filler comprises CaCO₃.Further, the construction material 302 may comprise a thermalstabilizer, calcium stearate, and/or at least one wax, in some aspects.In some aspects, the polymeric resin is between 45% and 80% of theconstruction material by weight or mass. In some aspects, the fillerscomprise between 0.14% and 50% of the construction material by weight ormass. In an aspect, CaCO₃ comprises between 0.14% and 50% of theconstruction material by weight or mass. In some aspects, the TiO₂comprises less than 7% of the construction material by weight or mass.In some aspects, the polymer-based construction material is a cellularor foamed material. Further, the polymer-based construction material 302comprises a first surface 304, and a second surface 312 opposite thefirst surface 304.

Contrary to a common belief in the industry that painting polymer-basedconstruction materials must happen within seconds of increasing thesurface energy of the materials, the combination of the compositions andthe preparations/treatments described herein may facilitate increasedsurface energy ≥40 dynes/cm² that persists within 20% for at least threedays. Accordingly, in an aspect, the polymer-based construction material302 is treated such that the surface energy of the first surface 304 isincreased to a predetermined value that persists within 20% of thepredetermined value for at least 3 days. The predetermined value can be≥40 dynes/cm². For example, the polymer-based construction material 302may be treated as discussed in relation to FIGS. 2A and 2B.

Further, the polymer-based construction material 302 comprises a gauge(thickness) 308, a length 306, and a width 318. The gauge 308 may be anythickness and may vary based on the intended use. In some aspects, thegauge 308 is between 0.10 inches and 2.00 inches. In some aspects, thegauge 308 is between 0.125 inches and 1.75 inches. In some aspects, thegauge 308 is between 0.25 inches and 1.5 inches. In some aspects, thegauge 308 is between 0.5 inches and 1.0 inch. In an aspect, the gauge308 is 0.25 inches.

The length 306 may be any length and may vary based on the intended use.In some aspects, the length 306 is between 0.5 feet (ft.) and 60 ft. Inan aspect, the length 306 is between 1.0 ft. and 50 ft. In some aspects,the length 306 is between 2 ft. and 30 ft. In some aspects, the length306 is between 8 ft. and 20 ft. In an aspect, the length 306 is between9 inches (0.75 ft.) and 36 inches (3 ft.). In an aspect, the length 306is between 12 inches (1 ft.) and 24 inches (2 ft.).

The width 318 may be any width and may vary based on the intended use.For example, a polymer-based construction material intended for use as asiding component may be a first width, while a polymer-basedconstruction material intended for use as a trim board may be a secondwidth, while a polymer-based construction material intended for use as aconstruction accessory may be a third width, and so on. In some aspects,width 318 is between 12 inches (1 ft.) and 80 inches (6.6 ft.). In someaspects, width 318 is at least 15 inches (1.25 ft.), 24 inches (2 ft.),36 inches (3 ft.), or 48 inches (4 ft.). In some aspects, width 318 isless than or equal to 80 inches (6 ft. 8 inches). Additionally, in someaspects, a polymer-based construction material (such as constructionmaterial 302) can be cut into a selectable combination of uniform and/ornon-uniform widths of individual narrower sheets.

Although depicted as a uniformly flat surface, it will be understood bythose skilled in the art that the first surface 304 and/or the secondsurface 312 may be in any configuration. For example, the polymer-basedconstruction material may be manufactured such that the first surface304 substantially replicates what is commonly referred to as a“slatwall” pattern, “tongue and groove” pattern, a “shingle” or “shake”pattern, a “lap” pattern, or other similar patterns. Similarly, thesecond surface 312 may be shaped such that the gauge of any particularcross section of the polymer-based construction material is relativelyconsistent throughout the material. Additionally, or alternatively, thefirst surface 304 of the polymer-based construction material maysubstantially replicate wood grain patterns, natural or masoned stonepatterns, uniform or off-set brick patterns, or other similar patterns.

Various example aspects are described herein as comprising CaCO₃.However, it will be understood by those skilled in the art thatreferences to CaCO₃ are not intended to be—and should not be interpretedas—excluding other fillers described herein or otherwise limitingaspects described herein. For example, it is contemplated that anyfiller or combination of fillers described herein can be included withor replace CaCO₃ as a filler in any aspect described. In other words,CaCO₃ is used as an illustrative, and non-limiting, example.

Those skilled in the art will understand that many other methods forproducing a polymer-based construction material may be used inaccordance with aspects described herein. Further, it will be understoodin light of the description provided herein that the recited polymericcomposition comprising between 0.14% and 25% filler (such as CaCO₃) andat most 7% TiO₂ that is treated to have a surface energy of at least 40dynes/cm² through disclosed mechanical or non-mechanical methods is ableto have a surface energy that persists within 20% for at least threedays from the treatment of the surface. Accordingly, the specificcompositions, techniques, and surface treatments provided herein may becapable of achieving and maintaining a target minimal surface energycapable of allowing a sufficient bond strength between the polymer-basedconstruction material and the paint applied later in time (e.g., atleast three days after the extrusion of the polymer-based material).However, the absence of a particular production or manufacturing methodshould not be interpreted as limiting; rather, the absence is merely afunction of providing a clear description of the features describedherein. Accordingly, it will be understood that the method describedabove is merely an illustrative example and not intended to limit thescope of the aspects described herein. For example, the polymer-basedconstruction materials can be assembled to form a corner board, columnwrap, post cover, molding, or any other multi-component constructionmaterial. For another example, some aspects of the post-treatmentpolymer-based construction materials can have a surface energy highenough that traditional adhesives used for product labeling (such asmarketing, pricing, universal product code (UPC) labeling, or any otherlabels affixed to the surface via traditional adhesives) are relativelydifficult to remove without leaving an adhesive residue. Accordingly, insome aspects, the polymer-based construction materials are labeled withlow residual adhesive labels.

Turning to FIG. 4, a depiction of a selected subset of ASTM D2578 (2018volume of ASTM Tests for Chemical, Physical, and Optical Properties)test results 400 is provided in accordance with aspects describedherein. Generally, FIG. 4 depicts the surface energy of polymer-basedconstruction materials (e.g., PVC) manufactured and treated inaccordance with aspects described herein 402 compared to a traditionaland untreated construction material 404. The exemplary polymer-basedconstruction materials 402 were treated on day 0 to increase the surfaceenergy from the inherent surface energy to a predetermined value of 72dynes/cm². The traditional and untreated construction material 404 wasused as a control beginning on post-treatment day 26. The traditionaland untreated construction material 404 had a post-manufacturinginherent surface energy of 36 dynes/cm². The surface energy was tested,via ASTM D2578, every five to ten days. As depicted, the average surfaceenergy of the exemplary polymer-based construction materials 402remained at 72 dynes/cm² through day 508. In contrast, the surfaceenergy of the traditional and untreated construction material 404 fellrapidly from 36 dynes/cm² to 30 dynes/cm² by day 40.

In an example embodiment, the polymer-based construction comprises76.92% polymeric resin by weight or mass, 11.54% fillers (such as CaCO₃)by weight or mass, ≤1% TiO₂ by weight or mass, 5.58% BMW acrylicmodifiers by weight or mass, and ≤6% other additional ingredients byweight or mass.

In another example embodiment, the polymer-based construction materialcomprises 76.9% polymeric resin by weight or mass, 9.2% fillers (such asCaCO₃) by weight or mass, ≤3.1% TiO₂ by weight or mass, 5.6% HMW acrylicmodifiers by weight or mass, and ≤6% other additional ingredients byweight or mass.

In another example embodiment, the polymer-based construction materialcomprises 77.5% polymeric resin by weight or mass, 9.3% fillers (such asCaCO₃) by weight or mass, ≤3% TiO₂ by weight or mass, 5.6% HMW acrylicmodifiers by weight or mass, and ≤6% other additional ingredients byweight or mass.

In another example embodiment, the polymer-based construction materialcomprises 77.5% polymeric resin by weight or mass, 9.3% fillers (such asCaCO₃) by weight or mass, ≤2.5% TiO₂ by weight or mass, 5.6% HMW acrylicmodifiers by weight or mass, and ≤5.3% other additional ingredients byweight or mass.

In another example embodiment, the polymer-based construction materialcomprises 78.1% polymeric resin by weight or mass, 9.4% fillers (such asCaCO₃) by weight or mass, ≤3% TiO₂ by weight or mass, 5.6% HMW acrylicmodifiers by weight or mass, and ≤6% other additional ingredients byweight or mass.

In another example embodiment, the polymer-based construction materialcomprises 78.3% polymeric resin by weight or mass, 9.5% fillers (such asCaCO₃) by weight or mass, ≤0.8% TiO₂ by weight or mass, 5.7% HMW acrylicmodifiers by weight or mass, and ≤5.8% other additional ingredients byweight or mass.

In another example embodiment, the polymer-based construction materialcomprises 79.4% polymeric resin by weight or mass, 9.5% fillers (such asCaCO₃) by weight or mass, 0.0% TiO₂ by weight or mass, 5.8% BMW acrylicmodifiers by weight or mass, and ≤5.4% other additional ingredients byweight or mass.

In yet another example embodiment, the polymer-based constructionmaterial comprises 76.9% polymeric resin by weight or mass, 10.0%fillers (such as CaCO₃) by weight or mass, ≤2.4% TiO₂ by weight or mass,5.6% HMW acrylic modifiers by weight or mass, and ≤5.2% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 76.9% polymeric resin by weight or mass, 10.8% fillers (suchas CaCO₃) by weight or mass, ≤1.6% TiO₂ by weight or mass, 5.6% HMWacrylic modifiers by weight or mass, and ≤5.2% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 76.9% polymeric resin by weight or mass, 12.3% fillers (suchas CaCO₃) by weight or mass, 0.0% TiO₂ by weight or mass, 5.6% HMWacrylic modifiers by weight or mass, and ≤5.4% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 77.1% polymeric resin by weight or mass, 11.6% fillers (suchas CaCO₃), ≤0.8% TiO₂ by weight or mass, 5.6% HMW acrylic modifiers byweight or mass, and ≤4.5% other additional ingredients by weight ormass.

In another example embodiment, the polymer-based construction materialcomprises 76.9% polymeric resin by weight or mass, 12.3% fillers (suchas CaCO₃) by weight or mass, 0.0% TiO₂ by weight or mass, 5.6% HMWacrylic modifiers by weight or mass, and ≤5.2% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 48.2% polymeric resin by weight or mass, 40.1% fillers (suchas CaCO₃), ≤0.14% TiO₂ by weight or mass, 5.8% HMW acrylic modifiers byweight or mass, and ≤5.9% other additional ingredients by weight ormass.

In another example embodiment, the polymer-based construction materialcomprises 69.6% polymeric resin by weight or mass, 20.1% fillers (suchas CaCO₃) by weight or mass, ≤0.7% TiO₂ by weight or mass, 5.1% HMWacrylic modifiers by weight or mass, and ≤4.7% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 69.6% polymeric resin by weight or mass, 20.0% fillers (suchas CaCO₃) by weight or mass, ≤0.7% TiO₂ by weight or mass, 5.1% HMWacrylic modifiers by weight or mass, and ≤4.8% other additionalingredients by weight or mass.

In yet another example embodiment, the polymer-based constructionmaterial comprises 75.2% polymeric resin by weight or mass, 13.6%fillers (such as CaCO₃) by weight or mass, ≤0.8% TiO₂ by weight or mass,5.5% HMW acrylic modifiers by weight or mass, and ≤5.1% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 72.5% polymeric resin by weight or mass, 16.8% fillers (suchas CaCO₃) by weight or mass, ≤0.8% TiO₂ by weight or mass, 5.3% HMWacrylic modifiers by weight or mass, and ≤5.0% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 74.7% polymeric resin by weight or mass, 14.1% fillers (suchas CaCO₃) by weight or mass, ≤0.8% TiO₂, 5.4% HMW acrylic modifiers byweight or mass, and ≤5.2% other additional ingredients by weight ormass.

In another example embodiment, the polymer-based construction materialcomprises 69.5% polymeric resin by weight or mass, 20.1% fillers (suchas CaCO₃) by weight or mass, ≤0.7% TiO₂ by weight or mass, 5.1% HMWacrylic modifiers by weight or mass, and ≤4.9% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 76.2% polymeric resin by weight or mass, 14.0% fillers (suchas CaCO₃) by weight or mass, ≤0.8% TiO₂ by weight or mass, 3.9% HMWacrylic modifiers by weight or mass, and ≤5.3% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 69.5% polymeric resin by weight or mass, 20.0% fillers (suchas CaCO₃) by weight or mass, ≤0.7% TiO₂ by weight or mass, 5.1% HMWacrylic modifiers by weight or mass, and ≤5.0% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 70.6% polymeric resin by weight or mass, 20.3% fillers (suchas CaCO₃) by weight or mass, ≤0.8% TiO₂ by weight or mass, 3.6% HMWacrylic modifiers by weight or mass, and ≤5.0% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises 70.6% polymeric resin by weight or mass, 20.4% fillers (suchas CaCO₃) by weight or mass, ≤0.8% TiO₂ by weight or mass, 3.6% HMWacrylic modifiers by weight or mass, and ≤5.0% other additionalingredients by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises polymeric resin in the range of 70%-75% by weight or mass,CaCO₃ in the range of 15%-13% by weight or mass, and TiO₂ in the rangeof 0.8%-0.6% by weight or mass.

In another example embodiment, the polymer-based construction materialcomprises polymeric resin in the range of 73%-75% by weight or mass,CaCO₃ in the range of 15%-13% by weight or mass, and TiO₂ in the rangeof 0.8%-0.6% by weight or mass.

Many different arrangements of the various components depicted, as wellas components not shown, are possible without departing from the scopeof the claims below. Embodiments of our technology have been describedwith the intent to be illustrative rather than restrictive. Alternativeembodiments will become apparent to readers of this disclosure after andbecause of reading it. Alternative means of implementing theaforementioned can be completed without departing from the scope of theclaims below. Certain features and subcombinations are of utility andmay be employed without reference to other features and subcombinationsand are contemplated within the scope of the claims.

As used herein and in connection with the claims listed hereinafter, theterminology “any of clauses” or similar variations of said terminologyis intended to be interpreted such that features of claims/clauses maybe combined in any combination. For example, an exemplary clause 4 mayindicate the method/apparatus of any of clauses 1 through 3, which isintended to be interpreted such that features of clause 1 and clause 4may be combined, elements of clause 2 and clause 4 may be combined,elements of clause 3 and 4 may be combined, elements of clauses 1, 2,and 4 may be combined, elements of clauses 2, 3, and 4 may be combined,elements of clauses 1, 2, 3, and 4 may be combined, and/or othervariations. Further, the terminology “any of clauses” or similarvariations of said terminology is intended to include “any one ofclauses” or other variations of such terminology, as indicated by someof the examples provided above.

Clause 1. A method of preparing a polymer-based construction materialfor future surface painting, the method comprising: in response to atreatment of a surface of the polymer-based construction material,increasing a surface energy of the surface from a first surface energyto a second surface energy of at least 40 dynes/cm2, the polymer-basedconstruction material comprising a polymeric composition comprising apolymeric resin, a filler, and titanium oxide (TiO₂); wherein thesurface energy of the surface persists within 20% of the second surfaceenergy for at least three days from the treatment of the surface.

Clause 2. The method of clause 1, wherein the treatment comprises anon-mechanical treatment of the surface.

Clause 3. The method of clause 2, wherein the non-mechanical treatmentcomprises a plasma or corona treatment.

Clause 4. The method of clause 2 or 3, wherein the non-mechanicaltreatment comprises an application of a UV curable composition, the UVcurable composition including a monomer, oligomer, adhesion promoter,gloss adjusting fillers, photoinitiators, or pigments; and wherein themethod further comprises: curing the application of the UV curablecomposition with radiation from a mercury arc lamp, a microwave poweredsealed mercury arc lamp, or LED array; wherein the radiation is between350 nm and 420 nm.

Clause 5. The method of any of clauses 1 through 4, wherein thetreatment comprises a mechanical treatment of the surface.

Clause 6. The method of clause 5, wherein the mechanical treatmentcomprises sanding or scuffing the surface.

Clause 7. The method of any of clauses 1 through 6, wherein the surfaceenergy of the surface persists within 20% of the second surface energyfor at least one month from the treatment of the surface.

Clause 8. The method of any of clauses 1 through 6, wherein the surfaceenergy of the surface persists within 20% of the second surface energyfor at least three months from the treatment of the surface.

Clause 9. The method of any of clauses 1 through 6, wherein the surfaceenergy of the surface persists within 20% of the second surface energyfor at least twenty months from the treatment of the surface.

Clause 10. The method of any of clauses 1 through 9, wherein the TiO₂comprises ≤7% by weight or mass of the polymer-based constructionmaterial.

Clause 11. The method of any of clauses 1 through 10, wherein the CaCO₃comprises ≥8% by weight or mass of the polymer-based constructionmaterial.

Clause 12. The method of any of clauses 1 through 11, wherein thepolymer-based construction material is a siding component.

Clause 13. The method of any of clauses 1 through 11, wherein thepolymer-based construction material is a trim board.

Clause 14. The method of any of clauses 1 through 13, wherein thepolymer-based construction material comprises polyvinyl chloride.

Clause 15. A polymer-based construction material comprising: a polymericresin, a thermal stabilizer, calcium carbonate (CaCO₃), and titaniumoxide (TiO₂), wherein in response to a treatment of a surface of thepolymer-based construction material, the surface energy of the surfaceincreases from a first surface energy to a second surface energy of atleast 45 dynes/cm², and wherein the surface energy of the surfacepersists within 20% of the second surface energy for at least three daysfrom the treatment.

Clause 16. The polymer-based construction material of clause 15, whereinthe treatment comprises a non-mechanical treatment of the surface.

Clause 17. The polymer-based construction material of clause 16, whereinthe non-mechanical treatment comprises a plasma or corona treatment.

Clause 18. The polymer-based construction material of clause 16, whereinthe non-mechanical treatment comprises an application of a UV curablecomposition, the UV curable composition including a monomer, oligomer,adhesion promoter, gloss adjusting filler, photoinitiator, or pigment;and wherein the non-mechanical treatment further comprises: curing theapplication of the UV curable composition with radiation from a mercuryarc lamp, a microwave powered sealed mercury arc lamp, or LED array;wherein the radiation is between 350 nm and 420 nm.

Clause 19. The polymer-based construction material of any of clauses 16through 18, wherein the treatment comprises sanding or scuffing thesurface.

Clause 20. The polymer-based construction material of any of clauses 15through 18, wherein the surface energy of the surface persists within20% of the second surface energy for at least one month from thetreatment of the surface.

Clause 21. The polymer-based construction material of any of clauses 15through 18, wherein the surface energy of the surface persists within20% of the second surface energy for at least three months from thetreatment of the surface.

Clause 22. The polymer-based construction material of any of clauses 15through 18, wherein the surface energy of the surface persists within20% of the second surface energy for at least twenty months from thetreatment of the surface.

Clause 23. The polymer-based construction material of any of clauses 15through 22, wherein the polymer-based construction material is a sidingcomponent.

Clause 24. The polymer-based construction material of any of clauses 15through 22, wherein the polymer-based construction material is a trimboard.

Clause 25. The polymer-based construction material of any of clauses 15through 24, wherein the polymer-based construction material comprisespolyvinyl chloride.

Clause 26. A polymer-based construction material comprising: a firstsurface; a second surface, wherein the first surface and the secondsurface are formed from a common polymeric composition comprising apolymeric resin, calcium carbonate (CaCO₃), and titanium oxide (TiO₂);the first surface having a first surface energy of at least 45 dynes/cm²and the second surface having a second surface energy, the first surfaceenergy is greater than the second surface energy.

Clause 27. The polymer-based construction material of clause 26, whereinthe TiO₂ comprises ≤7% by weight or mass of the polymer-basedconstruction material.

Clause 28. The polymer-based construction material of clause 26 or 27,wherein the CaCO3 comprises >8% by weight or mass of the polymer-basedconstruction material.

Clause 29. The polymer-based construction material of any of clauses 26through 28, further comprising a third surface, wherein the firstsurface is at least partially covered by the third surface, and whereinthe third surface comprises a UV curable material, monomer, oligomer,adhesion promoter, gloss adjusting filler, photoinitiator, or pigment.

Clause 30. The polymer-based construction material of any of clauses 26through 29, wherein the surface energy of the surface persists within20% of the second surface energy for at least one month from thetreatment of the surface.

Clause 31. The polymer-based construction material of any of clauses 26through 29, wherein the surface energy of the surface persists within20% of the second surface energy for at least twenty months from thetreatment of the surface.

Clause 32. The polymer-based construction material of any of clauses 26through 31, wherein the polymer-based construction material is a sidingcomponent.

Clause 33. The polymer-based construction material of any of clauses 26through 31, wherein the polymer-based construction material is a trimboard.

Clause 34. The polymer-based construction material of any of clauses 26through 33, wherein the polymer-based construction material comprisespolyvinyl chloride.

Clause 35. The polymer-based construction material of any of clauses 15through 34, wherein the surface energy is at least 70 dynes/cm2.

Clause 36. The polymer-based construction material of any of clauses 15through 35, wherein the polymer-based construction material comprisespolymeric resin in the range of 70%-75% by weight or mass, CaCO₃ in therange of 15%-13% by weight or mass, and TiO₂ in the range of 0.8%-0.6%by weight or mass.

Clause 37. The polymer-based construction material of any of clauses 15through 35, In another example embodiment, the polymer-basedconstruction material comprises polymeric resin in the range of 73%-75%by weight or mass, CaCO₃ in the range of 15%-13% by weight or mass, andTiO₂ in the range of 0.8%-0.6% by weight or mass.

The invention claimed is:
 1. A method of preparing a polymer-basedconstruction material for future surface painting, the methodcomprising: in response to a treatment of a surface of the polymer-basedconstruction material, increasing a surface energy of the surface from afirst surface energy to a second surface energy of at least 40dynes/cm², the polymer-based construction material comprising apolymeric composition comprising a polymeric resin, a filler, andtitanium oxide (TiO₂); wherein the surface energy of the surfacepersists within 20% of the second surface energy for at least three daysfrom the treatment of the surface.
 2. The method of claim 1, wherein thetreatment comprises a non-mechanical treatment of the surface or amechanical treatment of the surface.
 3. The method of claim 2, whereinthe non-mechanical treatment comprises a plasma or corona treatment. 4.The method of claim 2, wherein the non-mechanical treatment comprises anapplication of a UV curable composition, the UV curable compositionincluding a monomer, oligomer, adhesion promoter, gloss adjustingfillers, photoinitiators, or pigments; and wherein the method furthercomprises: curing the application of the UV curable composition withradiation from a mercury arc lamp, a microwave powered sealed mercuryarc lamp, or LED array; wherein the radiation is between 350 nm and 420nm.
 5. The method of claim 2, wherein the mechanical treatment comprisessanding or scuffing the surface.
 6. The method of claim 1, wherein thesurface energy of the surface persists within 20% of the second surfaceenergy for at least one month from the treatment of the surface.
 7. Themethod of claim 1, wherein the surface energy of the surface persistswithin 20% of the second surface energy for at least three months fromthe treatment of the surface.
 8. The method of claim 1, wherein the TiO₂comprises ≤7% by weight or mass of the polymer-based constructionmaterial.
 9. The method of claim 1, wherein the CaCO₃ comprises ≥8% byweight or mass of the polymer-based construction material.
 10. Themethod of claim 1, wherein the polymer-based construction material is asiding component, trim board, deck board, shingle, corner board, or aportion of a column wrap, post cover, or molding.
 11. A polymer-basedconstruction material comprising: a polymeric resin, a thermalstabilizer, calcium carbonate (CaCO₃), and titanium oxide (TiO₂),wherein in response to a treatment of a surface of the polymer-basedconstruction material, a surface energy of the surface increases from afirst surface energy to a second surface energy of at least 45dynes/cm², and wherein the surface energy of the surface persists within20% of the second surface energy for at least three days from thetreatment.
 12. The polymer-based construction material of claim 11,wherein the treatment comprises a non-mechanical treatment of thesurface or a mechanical treatment of the surface.
 13. The polymer-basedconstruction material of claim 12, wherein the non-mechanical treatmentcomprises an application of a UV curable composition, the UV curablecomposition including a monomer, oligomer, adhesion promoter, glossadjusting filler, photoinitiator, or pigment; and wherein thenon-mechanical treatment further comprises: curing the application ofthe UV curable composition with radiation from a mercury arc lamp, amicrowave powered sealed mercury arc lamp, or LED array; wherein theradiation is between 350 nm and 420 nm.
 14. The polymer-basedconstruction material of claim 12, wherein the mechanical treatmentcomprises sanding or scuffing the surface.
 15. The polymer-basedconstruction material of claim 11, wherein the surface energy of thesurface persists within 20% of the second surface energy for at leastone month from the treatment of the surface.
 16. The polymer-basedconstruction material of claim 11, wherein the polymer-basedconstruction material is a siding component, trim board, deck board,shingle, corner board, or a portion of a column wrap, post cover, ormolding.
 17. The polymer-based construction material of claim 11,wherein the polymer-based construction material comprises polyvinylchloride.
 18. A polymer-based construction material comprising: a firstsurface; a second surface, wherein the first surface and the secondsurface are formed from a common polymeric composition comprising apolymeric resin in the range of 70%-75% by weight or mass, calciumcarbonate (CaCO₃) in the range of 15%-13% by weight or mass, andtitanium oxide (TiO₂) in the range of 0.8%-0.6% by weight or mass; thefirst surface having a first surface energy of at least 45 dynes/cm² andthe second surface having a second surface energy, the first surfaceenergy is greater than the second surface energy.
 19. The polymer-basedconstruction material of claim 18, further comprising a third surface,wherein the first surface is at least partially covered by the thirdsurface, and wherein the third surface comprises a UV curable material,monomer, oligomer, adhesion promoter, gloss adjusting filler,photoinitiator, or pigment.
 20. The polymer-based construction materialof claim 18, wherein the surface energy of the first surface persistswithin 20% of the second surface energy for at least one month from thetreatment of the surface.